Universal process monitoring -
Flexible. Precise. Efficient.
Critical process parameter with MOLDUNI simply measure:
Flow velocity, solidification behavior and shrinkage behavior -
precise, contactless and reliable.
The exact fingerprint of your shaping process.
With the sensor package MoldUni several quality parameters, such as
- the flow front
- the flow velocity
- the solidification velocity
- the downturn time
recorded and evaluated at just one measuring position in the cavity. This opens up completely new possibilities for monitoring, optimization, prediction, quality assurance and documentation of your injection molding process.
Easy assembly.
Robust sensor technology.
The sensor is mounted in a blind hole and has no contact with the filling medium. The associated sensor unit can be mounted on the mold or on the respective machine.
Applications
Cyclic quality monitoring in injection molds
Together with Haidlmair our sensor technology MoldUni was presented at the K2022 in Düsseldorf. In the mold Sixpack (beverage holder) our sensor technology was used to continuously monitor the component quality. Special features of this component or injection mold are:
- Use of the FDU (Flat Die Unit) as a hot runner system
- Combined with Moldsonics MoldUni sensor technology, real-time monitoring and documentation of production through mold monitoring was used
- Short cycle times due to hybrid built mold (conventional and 3D printed)
Monitoring of component shrinkage
Since the MoldUni sensor system can determine the exact shrinkage time of the injection molded part from the mold wall, it is possible to monitor the shrinkage behavior.
This means that it is possible to determine during the injection molding process whether a component meets the specified shape and dimensional tolerances.
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Questions and answers
What output signal do I get?
With MOLDUNI, you receive an analog voltage signal in the range from 0 to 10 volts. This signal can be processed directly with an analog-to-digital converter, for example, in order to evaluate precise process data in real time.
What does the output signal make possible?
The voltage signal provides a characteristic ultrasonic curve that offers detailed insights into the processes in the injection mold. Various important parameters can be determined from this curve, including
- Flow front detection: Detection of the exact moment when the melt reaches the defined position.
- Flow front speed: Determination of the speed at which the melt front spreads in the mold.
- Surface layer growth (crystallization): Monitoring of solidification layer formation along the mold wall.
- Shrinkage time: Time at which the component detaches from the cavity wall.
-Thermal equilibrium: Analysis of the temperature distribution in the mould to optimize the heat balance.
How many sensors can be connected to one electronic unit?
Up to two sensors can be connected to a MOLDUNI electronic unit at the same time.
Why two sensors?
- Measurement at different positions: The use of two sensors makes it possible to monitor several measuring points in the mold, e.g. to precisely determine the flow rate by recording the time difference between two positions.
- Extended analysis: Several measuring points allow a detailed analysis of the solidification and shrinkage behavior across different areas of the component.
For applications with more complex requirements or additional measuring points, several electronic units can be combined.
Where is the best place to position the sensor?
The ideal positioning of the MOLDUNI sensor depends heavily on the respective application. We will be happy to coordinate the optimum positioning with you individually in order to achieve maximum measurement results.
Basic recommendations:
- Close to the sprue:
The closer the sensor is positioned to the sprue, the longer the measurement process can be carried out and the more measurement data can be generated. - Monitor problem areas:
It is advisable to place the sensor in areas where problems frequently occur, e.g. incomplete filling, air pockets or solidification defects. - Value-added position:
The sensor should ideally be used where its results offer the greatest added value - for example at critical points with tight tolerances or complex geometries.
In what temperature range can MoldUni be used?
The MoldFront ultrasonic sensor system can be operated in different temperature ranges:
- Standard version: Suitable up to 120°C, ideal for typical applications in plastic injection molding.
- Special high-temperature variant: Suitable for temperatures up to 250°C, specially developed for high-temperature applications, e.g. for thermosets, elastomers or RTM processes.
Summary:
The standard version of MoldFront covers typical processes up to 120°C. For particularly demanding applications, the special high-temperature version is available with a resistance of up to 250°C, without compromising on measuring accuracy.
The electronic unit can withstand an operating temperature of 60°C permanently.
Does the sensor need to be serviced or calibrated?
The MoldUni ultrasonic sensor is basically calibration- and maintenance-free. Once installed, the sensor works reliably without regular adjustments or calibrations, which reduces operating costs and increases efficiency.
Maintenance recommendation:
However, to ensure smooth operation even in demanding applications, we recommend one to two functional checks per year, depending on the operating environment. These checks include:
- Check the sensor function and the electronic unit.
- Visual inspection for possible contamination or mechanical damage in the vicinity of the sensor.
- Check the installation, especially in applications with high pressures or temperatures.
What are the dimensions of the sensor system?
Sensor: ∅ 10 x 8 mm, with a cable length of 300 mm (individual cable lengths and plug-in cable extensions are optionally available)
Electronic unit: 180 x 158 x 47 mm
How is the sensor system electrically supplied?
The MoldUni ultrasonic sensor system is supplied electrically via a standard 24 V DC power supply. This supply voltage is widely used in industry and enables simple integration into existing control systems.
Details of the power supply:
- Voltage range: 24 V DC ±10 %
- Power consumption: Low power consumption for energy-efficient operation.
- Suitable for industrial use: Protection against voltage peaks and interference ensures safe operation even under demanding conditions.
